LPA (Layered process audit) are processes that aim to increase the quality of finished products, by auditing the production process and inspecting how products are made, instead of just observing the finished version.
This process aims at conducting regular internal audits, in every hierarquical level. The in-depth analysis is part of a Quality Management System that helps the organization to detect gaps and areas of improvement in the company.
With LPAs, every layer of management participates in daily checks of high-risk processes, which requires a solid plan and a prepared team. Every layer uses PDCA processes to audit their attributed area.
Efficient LPA Audits respect a 5 steps processes, as following:
Evaluate which ones are the best practices for a correct LPA Audit process applications.
Create a LPA dedicated team that is trained and focused in these processes, in order to become better and faster over time.
Write Audit questions in order to create a form and standardized analysis, to avoid biased results.
Create an Audit plan with the goal of inspecting the production process for one product, and execute it.
Measure and improve the results and use the information to improve continuously the processes.
With a continuous improvement focus, the LPA Audit will make it possible to correct existing mistakes quickly and then, use information to optimize all processes that were audited.
Digital platforms allow to centralize data and create digital checklists to support the process. They are are available for different management layers, providing field workers with information to execute their process and give feedback. It provides management teams with analytics about execution facilitating the detection of potential improvements.
Automatic reports and dashboards are generated according to execution. Data is displayed in a visual way that facilitate both comprehension and analysis. It becomes easier to understand where and why problems happen and take corrective measures.
Process digitalization efficiently combined with IoT increases visibility and control over any process. It allows to easily visualize through a see-through screen, information and guides about process, and, data from equioment behaviour, superimposed in the real industrial environment. Additionally, by collecting visual evidence of the executed tasks, it is possible to confirm the correct execution, reducing the possibility of unexpected errors.
A unique platform that combines process digitalization with IoT data extracted from the factory floor. The platform organizes worflowss according to different needs and users. Not only the platform deploys valuable inputs but also generates automatic reports that gathers the different hierarquical levels observations and notes. This facilitates decision-making but also allows it to be more concise.